Got tired of worrying about the stock knuckles... so I built new ones...
#1
Got tired of worrying about the stock knuckles... so I built new ones...
... sort of.
I'm sure by now you are all aware that I bent a stock knuckle back in March, if you're not read this thread first, it will get you up to speed.
https://www.ranger-forums.com/forum2...ad.php?t=82721
Anyway, back to the story.
To fix the problem and prevent it from happening again I picked up another set of knuckles. Had them sand blasted to clean off the years of grime (they are off an 01-05 ish truck (not sure what year exactly, it was a fire victim), then set off to work building gussets for them.
As you can see I boxed in the 'neck' of the knuckle, where the previous one bent. I did this with 3/16" steel plate, and fully TIG welded it. I also added gussets to the bottom of the knuckle around the lower ball joint (not pictured).
You may also have noticed that I changed the steering. I decided since I was working on it anyway I would give heims a shot on the outer in an effort to eliminate the pesky stock outer tie rod ends. To do this and get around the tapered hole I drilled it out to 5/8" and then TIG welded a chromoly weld on reinforcement washer to to the top and bottom. Along with adding a double sheer tab to the top. The heims are 3/4" FK JMX series heims and the tie rods are 1 1/2" .120 DOM.
Note: I'm sure somebody will mention it so I'll just say it first. No, you are not supposed to weld to cast steel. Cast steel is brittle and welding to it makes it worse (in some cases). Thus why I TIG welded the gussets to the knuckle. I've had much much better success with TIG welding to cast than MIG welding to cast. Also, since all I did was reinforcing and not actually adding any load bearing parts I am not worried about being cast steel.
Without further ado... pics!
I'm sure by now you are all aware that I bent a stock knuckle back in March, if you're not read this thread first, it will get you up to speed.
https://www.ranger-forums.com/forum2...ad.php?t=82721
Anyway, back to the story.
To fix the problem and prevent it from happening again I picked up another set of knuckles. Had them sand blasted to clean off the years of grime (they are off an 01-05 ish truck (not sure what year exactly, it was a fire victim), then set off to work building gussets for them.
As you can see I boxed in the 'neck' of the knuckle, where the previous one bent. I did this with 3/16" steel plate, and fully TIG welded it. I also added gussets to the bottom of the knuckle around the lower ball joint (not pictured).
You may also have noticed that I changed the steering. I decided since I was working on it anyway I would give heims a shot on the outer in an effort to eliminate the pesky stock outer tie rod ends. To do this and get around the tapered hole I drilled it out to 5/8" and then TIG welded a chromoly weld on reinforcement washer to to the top and bottom. Along with adding a double sheer tab to the top. The heims are 3/4" FK JMX series heims and the tie rods are 1 1/2" .120 DOM.
Note: I'm sure somebody will mention it so I'll just say it first. No, you are not supposed to weld to cast steel. Cast steel is brittle and welding to it makes it worse (in some cases). Thus why I TIG welded the gussets to the knuckle. I've had much much better success with TIG welding to cast than MIG welding to cast. Also, since all I did was reinforcing and not actually adding any load bearing parts I am not worried about being cast steel.
Without further ado... pics!
Last edited by rngprerunner; 06-22-2009 at 04:34 PM.
#4
#6
#9
#14
It's still a Dixon kit, the only part that I've changed is the tie rod.
I'm surprised about the ball joint to be honest too. Hitting the rock just proved how strong they actually are. I would have figured the tire and or wheel would have gone too before the knuckle, but whatever...
I'm surprised about the ball joint to be honest too. Hitting the rock just proved how strong they actually are. I would have figured the tire and or wheel would have gone too before the knuckle, but whatever...
Thread
Thread Starter
Forum
Replies
Last Post
Bs03fx4
OLD - Interior, Exterior, Electrical, & Misc.
15
12-14-2010 04:12 PM
Want to Buy: Stock 4x4 knuckles, 1998-2000
victory80
OLD - Engine & Drivetrain
3
03-02-2010 08:42 PM
blkranger
4.0L OHV & SOHC V6 Tech
19
06-12-2005 08:22 AM